Advantages of Condition Monitoring System

A lifeguard is to the ablutophobic (water-fearer), so is a Condition-Monitoring System to the Maintenance Heads and Reliability Engineers! Being the production unit’s front line, the Servicing team keeps running on toes to ensure all the equipment is efficient and under operation. 

A condition-monitoring system prescribes the need for maintenance, prioritizes the equipment to be overhauled, especially when the entire production line is under-performing, and recommends remedial measures, to prevent downtime. Further, it eases the Maintenance team’s job by remotely monitoring difficult-to-reach locations on a cooling-tower, blast furnaces in a steel plant, capping machines in the bottling plant, etc. 

Advantages of Condition Monitoring System

The main advantages of a Condition Monitoring System are:

  1.  Reduce the Maintenance costs – A recent survey conducted by the Global Vibration Monitoring Service Providers agrees that 90% of the Manufacturing industries adopt Vibration Monitoring Systems to maintain assets based on fundamental, actual degradation mechanisms. A real-time monitoring system potentially saves 30% of the Maintenance cost.
  2.  Increase the production capacity – A condition-monitoring system enables Predictive Maintenance and gives a better understanding of asset health. Capturing live-data, trends, and data analysis of the assets helps plant engineers to know the unique quirks of each purchase. Moreover, scheduling maintenance to prevent a breakdown improves the availability of the machine, increases the Mean Time Between Failure (MTBF), and reduces the repair time leading to rising in production.
  3.  Enhance asset lifecycles – Preventing unexpected shutdowns protects the equipment’s physical integrity, thus avoiding any secondary damage to connected components. Lower is the replacement of spares; higher is the life of the equipment. The long life of equipment implements reduction in OPEX (operational Expenses) and CAPEX (the need to invest in new capital assets).
  4.  Decrease the inventory of spares – The clear insights into the health of the equipment encourage careful planning of spares and resources. It consequently reduces the wrench time, needs for surplus components, and additional warehouses.
  5.  Improve Reliability – Condition Monitoring coupled with Diagnostic services detects the root cause of the equipment’s abnormal behavior and optimizes its KPIs. The instantaneous data obtained from pumps, motors, fans, and gearboxes is invaluable, and its analysis certainly minimizes future defects and asset failures.

Infinite Uptime offers cost-effective Diagnostic Services and Predictive Maintenance solutions aptly named Industrial Data Enabler (IDE) vEdge, which collects streaming equipment data. The momentary information on the dashboard seeks to decrease or eliminate unexpected machine breakdowns. Moreover, 80% of the rotating equipment faults, viz motors, pumps, fans, blowers, spindle, and gearboxes, can be predicted with 20% of the costs. The remote-monitoring follows the social norms and ensures the safety and security of the equipment and the workforce.

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